Hi I have 2004 3.0i with manual transmission. I bought the car in 2023, with a relatively high mileage (158k miles), and since then I've put 15k miles on it. I know it's not a new car, but I want to make it as reliable as possible. From the beginning there was a clunking sound when starting and when shifting into 2nd or 3rd gear. It was quite annoying so I had the drive shaft rebuilt, the dual mass flywheel replaced and the complete clutch assembly (Sachs DMF, LUK clutch set). This was last year in April, a small clunking noise still remained but was quite tolerable. I drove the car for about 6000 miles and a different sound was coming from the front of the car more and more, especially when I was rolling at low speed and I would release the clutch and then release it, then a quite loud clunking sound could be heard and also when I pressed the accelerator after engine braking. Meanwhile, when stopping, knocks could be heard again, just as before the DMF change. In December last year I replaced the differential and rear subframe carrier bushings with polyurethane, fitted a shorter ratio differential with a Blackline helical LSD( the LSD is new, in the diff replaced bearings, and adjusted backlash, etc) and a pair of new output shafts. I used the car almost nothing over the winter, then decided to replace the DMF and clutch again in the spring. I now have a LUK made DMF and clutch kit in the car, by another mechanic, who experienced in BMW mechanics. Unfortunately, after the first test drive, the drivetrain makes the same, if not worse, noises while driving, with the same clunking noises when stopping as with the previous DMF. The mechanic showed me the dismantled former DMF and the clutch (both were worn (the clutch auto adjuster was in the default position, but the disc was worn, the spring clip was broken, possibly a mistake of the former mechanic). Unfortunately, I'm now out of ideas of what else to replace, or what make of DMF and clutch kit to put in the car if I want a completely smooth and soundless drivetrain. Is it possible to buy a faulty part from the factory again? I bought it from a reputable, serious car parts shop, with an invoice and a warranty, which I will of course enforce. Is it possible that the second mechanic made a mistake? He told me that he had the same symptoms with his own van, but that they disappeared after a few thousand kilometres (I find that very hard to believe).
Thanks for help, and sorry for my bad english language.
Thanks for help, and sorry for my bad english language.